Modular control system and method for water heaters

Abstract

A water heating system includes a tank, one or more heating elements mounted on the water heating system, and a first controller mounted on the tank. The first controller is coupled to the one or more heating elements and includes logic to activate and deactivate the heating elements according to a first threshold value. The water heater also includes a second controller that is selectively coupled to the first controller and configured to communicate the first threshold value to the first controller, and perform an additional function related to the operation of the water heater. The first controller is configured to receive the first threshold value from the second controller and control the one or more heating elements based on the received threshold value, and to control the one or more heating elements mounted on the water heating system in a physical absence of the second controller.

What is claimed is: 
     
       1. A water heating system having a modular control system, comprising:
 a tank; 
 a heating element supported by the tank; 
 a first controller supported by the tank, the first controller coupled to the heating element, the first controller including logic to activate and deactivate the heating element according to a first threshold value; and 
 a second controller selectively coupled to the first controller and configured to
 communicate the first threshold value to the first controller, and 
 perform an additional function related to the operation of the water heater; and 
 
 wherein the first controller is configured to control the heating element mounted on the water heating system in an absence of the second controller. 
 
     
     
       2. The water heating system of  claim 1 , wherein the second controller is configured to receive information from a user for determining the first threshold value. 
     
     
       3. The water heating system of  claim 1 , wherein the second controller is configured to determine the first threshold value based on a first algorithm. 
     
     
       4. The water heating system of  claim 3 , wherein the first algorithm includes a usage history algorithm that determines the first threshold value and a second threshold value based on the usage history of the heating element. 
     
     
       5. The water heating system of  claim 4 , wherein the second controller is configured to communicate with the first controller the second threshold value, and wherein the first controller activates and deactivates the heating element based on the first threshold value and the second threshold value. 
     
     
       6. The water heating system of  claim 1 , wherein the second controller includes a display. 
     
     
       7. The water heating system of  claim 1 , wherein the additional function performed by the second controller includes storing activation and deactivation information of the heating element. 
     
     
       8. The water heating system of  claim 1 , wherein the first controller is configured to communicate information pertaining to the activation and deactivation of heating element to the second controller. 
     
     
       9. The water heating system of  claim 1 , wherein the first controller and the second controller communicate wirelessly. 
     
     
       10. The water heating system of  claim 1 , wherein the first controller has a first housing that covers components of the first controller, and wherein the second controller has a second housing, separate from the first housing, covering components of the second controller. 
     
     
       11. The water heating system of  claim 1 , wherein the second controller is configured to send a wireless command to the first controller instructing the first controller when to activate the heating element. 
     
     
       12. The water heating system of  claim 1 , wherein the second controller is not directly coupled to the heating element. 
     
     
       13. The water heating system of  claim 1 , wherein the second controller is located remotely from the tank. 
     
     
       14. The water heating system of  claim 1 , wherein the second controller is selectively physically coupled to the first controller. 
     
     
       15. The water heating system of  claim 1 , wherein the first controller includes an input device that is configured to receive information regarding the first threshold value. 
     
     
       16. A water heating system having a modular control system, comprising:
 a tank; 
 one or more heating elements mounted on the water heating system; 
 a first controller mounted on the tank and having a first communication port, the first communication port having a first wireless transceiver, and the first controller including logic for activating and deactivating all of the one or more heating elements mounted on the water heating system based on a first threshold; and 
 a second controller selectively coupled to the first controller via the first communication port, the second controller configured to wirelessly send information regarding the first threshold to the first controller, 
 wherein the first controller is configured to wirelessly communicate information regarding the activation and deactivation of the one or more heating elements to the second controller, and 
 wherein the first controller is configured to control the activation and deactivation of all the one or more heating elements in the absence of the second controller. 
 
     
     
       17. The water heating system of  claim 16 , wherein the second controller has logic configured to receive, via a wireless communication device, data indicative of an input for establishing a set point to be used for determining the first threshold. 
     
     
       18. The water heating system of  claim 17 , wherein the logic of the second controller is configured to transmit, via the wireless communication device, information pertaining to operation of the water heating system to a remote device. 
     
     
       19. The water heating system of  claim 16 , wherein the first controller has a first housing that covers components of the first controller, and wherein the second controller has a second housing, separate from the first housing, covering components of the second controller. 
     
     
       20. The water heating system of  claim 19 , wherein the tank has a compartment, wherein the first controller resides in the compartment, and wherein the second housing has a rim inserted into the compartment and contacting a wall of the tank defining the compartment.